INTOUCH® is a regular publication of the Polyurethane Foam Association. It measurements are also made at other percentages of indentation.

In
covers topics of interest to users of flexible polyurethane foam and is designed
as a quick reference e for background information on key issues. To get more the United States, 65% IFD is used in combination with 25% IFD to
detailed information about a particular topic, consult a PFA member. determine foam Compression Modulus (also known as Support
How Foam Firmness Affects Factor). Compression Modulus is the ratio of the 65% IFD value
Performance divided by the 25% IFD. The importance of including Compression
Within the upholstered furniture, mattress and carpet Modulus in foam specifications will be discussed briefly in this bulletin.
cushion industries, the two most commonly used A complete description of Compression Modulus is available in
specifications for flexible foam are firmness and density. IN•TOUCH® Volume 3, Number 1.
Firmness should never be specified without density. Specification of
either property alone is not sufficient. This issue of IN•TOUCH®
examines the issue of firmness specification and discusses ways foam
firmness can be used together with other specification values to
improve finished product performance and customer satisfaction.

Foam Firmness Measurements

IFD For Most Furniture And Bedding Applications
In upholstered furniture and mattresses, foam firmness is described
using a standard measurement value called IFD (Indentation Force
Deflection). An IFD number represents the pounds of force required to
indent a foam sample by a specified percentage of its original thickness.
Specially designed equipment is required to measure IFD. In most
cases, a 50 sq. in. round indentor plate is attached to a vertical piston-
like cylinder having a precisely calibrated stroke. Following the
standard procedures detailed in ASTM D3574, firmness is measured on
foam samples having a square surface area of at least 15" x 15". In
practice, larger sample sizes are often preferred with the objective of
duplicating the response of the end-use cushion product. (See
IN•TOUCH® Volume 4, Number 2.) Sample dimensions, including
surface area and thickness are critical to IFD testing results and will be Flexible foam is a network of tiny interl-
explained later in this issue. Height measurement accuracy is also ocking support cells. Each cell is made up
critical to obtaining consistent IFD results. of struts and windows. Elastic plastic
Surface firmness is measured at 25% sample indentation (25% formed into this unique cellular structure
IFD). As an example, using a 4" thick sample, the 25% IFD reading allows the system to compress and recover
would be made while the foam is indented to 3" height under the in response to applied loading and
piston foot plate (25% deflection of the sample height). IFD unloading conditions.
CFD For Carpet Cushion, Firmer
Foams & Undersized Samples
With carpet cushion, very firm foams, or undersized foam
samples, CFD (Compression Force Deflection) is often used instead of
IFD. CFD is the force in pounds required to compress an entire sample
surface area to 50% sample height deflection. The CFD measurement
is made using the same laboratory equipment as in the IFD
procedure. To perform a CFD measurement, a sample with minimum
surface dimensions of 2" x 2", and a thickness of 3/4", is required.
Thinner carpet cushion foam samples must be stacked to achieve the
minimum height requirement. The maximum height for CFD
measurement is limited to 75% of the width or length of the sample
size. So, a 4" x 4" sample could not be thinner than 3/4", or thicker
than 3". Surface area is also limited to a size that can be completely
covered by the compression plate.
To make a CFD measurement, the entire surface of the foam
sample is compressed beneath the plate.
CFD measurements are frequently made at 25%, 65% or other
height compressions as agreed upon by supplier and foam purchaser.
Non-standard measurements may be necessary for very firm
structural foams, or undersized test samples. Firmness, in terms of
specifying desired foam softness or hardness, is certainly one of the
most important characteristics of flexible foam. But, other physical
characteristics must also be considered when working with this
versatile cushioning material. CFD should never be specified without
density.
Firmness And Density:
Independent Properties
Flexible polyurethane foam is made up of a network of cellular
shapes comprised of tiny struts and cell windows. The struts form the
exterior support structure of the cells, while the windows are voids
which are created as foam bubbles burst during the foam production
process. Common struts are shared among cells to create a unified
material with good structural integrity and handling strength. This
unique structure complements the elasticity of the plastic material
allowing polyurethane cells to compress and recover in response to
applied load, much like coil springs. The amount of plastic material
contained in a given volume is critical to the long term performance
of flexible foam. The number of pounds of material contained in a
cubic foot (12" x 12" x 12") is the density of the foam sample. (See
IN•TOUCH® Volume 1, Number 2.)
Lower density values mean there is less cellular material avail-
able to perform under loading conditions. On the other hand, higher
density products have more strut material to provide desired long
term cushioning performance.
Using various chemical formulation and processing
technologies, foam firmness can be controlled during the production
process independent of the density within broad ranges. A high
density foam can be produced to have low or high IFD values. Lower
IFD numbers indicate softer foam, while higher values represent
firmer cushioning products.
Like all load-bearing structural materials, with
extreme or repeated flexing, the physical properties of foam will
change as strut fatigue occurs. In flexible foam cushioning, fatigue
may be observed as changes in physical strength, height, recovery or
firmness properties. Higher density foam products usually exhibit
better resistance to fatigue than lower density products. Simply stated,
there's more load bearing material to share the work. Depending
on the end-use application, certain fatigue loss characteristics may be
more acceptable than others. To avoid undesirable fatigue losses,
cushioning application objectives and performance requirements
should be shared with your foam supplier. A minimum density should
always be established in conjunction with a firmness specification.
As a general rule, with conventional virgin polyurethane foam,
higher density products (1.8 pcf or greater polymer density) can
provide excellent long-term performance with less firmness loss in use.
Some Firmness Change Should Be Anticipated
With all types of cushioning materials, some firmness change
should be expected in normal use. A slight amount of softening is
normal with virgin polyurethane products. However, some filled
foams having a high percentage of filler material may exhibit
increased firmness as inert additives compact (see IN•TOUCH®
Volume 1, Number 2). As a rule, firmness change with foam
cushioning will be less than with alternative cushioning materials such
as polyester and natural fibers. Your foam supplier can provide
information on the amount of firmness change that should be
expected for particular grades of foam used in your application.
 A Case For Standardized dimensions. For more information on IFD variation based on
Sample Sizes surface dimensions, contact a PFA member, or write: the
Recent work by the Joint Industry Polyurethane Foam American Furniture Manufacturers Association, P.O. Box HP-7,
Committee (JIPFC) provides insight into the affect of foam test High Point, NC 27261.
sample size on IFD measurement. While charts are available to
help convert 25% IFD from one sample thickness to another,
there is no conversion formula to project IFD variation resulting
from differences in surface area dimensions. JIPFC IFD testing
of identical grades of foam cut to different surface area
dimensions demonstrated that sample size has a significant
affect on IFD measurement.
IFD values increase as surface area becomes larger. This
means that the measured IFD will be greater for a foam sample
measuring 24" x 24" than for an identical grade and thickness
of foam having 15" x 15" surface dimensions. This
phenomenon can be explained by observing the IFD
measurement procedure. On larger sample sizes there is more
edge bow around the indentor plate. The resulting increased
surface tension affects IFD measurement. To simulate the
surface tension "edge effect" that occurs with full-size cushions Sample size can create different “edge
in use, JIPFC recommends that IFD be specified based on a effects” in IFD measurement. JIPFC
minimum sample size of 20" x 20" x (purchased thickness). recommends a minimum sample size of
20” x 20” x (purchased thickness) to
In all cases the end-user and foam supplier must agree to more closely simulate the natural “edge
specify and mea-sure IFD using identical foam sample effect” that occurs in actual cushion use.

Specifying Ideal Firmness In
Upholstered Furniture
Cushion firmness is affected by foam firmness, cushion
surface dimensions, cushion thickness, surface wrap and layered
construction, amount of cushion oversizing, upholstery fabric, and
cover upholstering technique (tight cushion vs. loose cushion
construction). Spring system, decking construction and Total Vertical
Motion (TVM) will also impact the feel of the cushion and must be
considered when specifying foam firmness. (See IN•TOUCH® Volume
2, Number 3.)
For most applications, foam firmness should be specified to allow
a seated person to sit slightly "into the cushion" rather than on top of
it. The objective is to reduce interfacial pressure to a point where
body weight is distributed evenly without hardness or allowing the
springs and decking system to be felt underneath.
Depending on the total design of the seating system, IFD
specifications may range from as low as 10 lbs. in thick "frumpy"
cushions and loose pillow back constructions to as high as 45 lbs. for
thin cushions over solid decking as might be found in a commercial
bar stool. In all cases, there's no textbook answer to specifying
firmness. A slight change in seating construction can cause two
identical cushions to feel very different. After carefully considering
every functional and construction aspect of the seating system,
experimentation is required to determine the best foam firmness for a
particular application.
Relating Cushion
Fatigue To Firmness
Roundtable discussions conducted by the Joint Industry
Polyurethane Foam Committee concluded that some cushion fatigue and
softening problems may be due to specifying too low an IFD in seating
applications. Since all virgin foam products will lose firmness with use,
IFD must be specified to allow for anticipated softening. Starting with too
soft a foam may have showroom appeal, but can result in later durability
problems and customer complaints. Seating may begin to "bottom out"
as the cushion exhibits normal wear characteristics.
The JIPFC report also noted that durability problems may result
from excessive cushion deflection. While some degree of ride is
desirable, excessive vertical motion may create unusual stress within the
foam cell structure that can contribute to later performance problems.
These problems can be greatly reduced or eliminated through
careful consideration of all the factors that affect IFD specification. New
"high performance" grades of flexible polyurethane foam also allow
specification of a soft surface feel without excessive vertical motion or
lack of deep down support. Your foam supplier can provide samples of
"high performance" foam cushioning products for evaluation.
Adjusting Firmness
Specification Using
Compression Modulus
As discussed earlier, Compression Modulus is determined by
dividing 65% IFD by 25% IFD. It is the relationship of surface
firmness to deep down support. In actual use, the surface firmness
(25% IFD) is a major contributor to the cushion "comfort" sensation,
while the deep down support (65% IFD) carries much of the load,
affecting ride and TVM.
With the introduction of "high performance" foams (characterized
by higher Compression Modulus values) adjustments in 25% IFD
specifications were required in order to successfully substitute the new
products for conventional foam grades.
Experience demonstrates that as Compression Modulus increases,
25% IFD specification can be decreased proportionately to maintain
seat height under load. Here's an example of how the new 25% IFD
value would be determined for a substitute "high performance" foam.
Assume that your supplier has provided physical values on a
conventional foam of 25% IFD = 25 lbs., 65% IFD = 50 lbs., with a
Compression Modulus of 2.0. The values would relate using this
formula: 50/2.0 = 25. To substitute a "high performance" foam
product with a Compression Modulus of 2.4, you would use the same
formula to find the new 25% IFD specification. The 65% IFD remains
constant to maintain desired seating height (50/2.4 = 21). The new
25% IFD is about 21 lbs. Reducing 25% IFD can create many
opportunities for product designers who are seeking to increase
surface softness without sacrificing support.
Conversely, the increased support provided by higher
Compression Modulus values may be useful in certain cushioning
applications. For insulating motion mechanisms and innerspring
bedding units, to add comfort to hard decking systems, or more
appeal to carpet cushion, the higher 65% IFD values may be
desirable. PFA members can help you develop specific foam
specifications to meet your application needs.
Summary
While firmness values are commonly used in specifying flexible
polyurethane foam, they should never be used as single specification
criteria. Other physical properties must also be specified to affect the
durability characteristics of the foam product. The following points relate to
all flexible polyurethane foam applications.
1. Surface firmness is expressed as a 25% IFD value. It is the number of
pounds of force necessary to indent a foam sample by 25% of its original
height.
2. IFD is measured differently than CFD. IFD indents a portion (50 sq.
in.) of the sample surface area. CFD compresses the entire sample surface
area.
3. Firmness is independent of density. High density foam can be
produced to be very soft or very firm, or any firmness in between.
4. Some change in firmness during end-use should be anticipated with
all foam products. As a general rule, higher density virgin foams will
exhibit less firmness loss.
5. Your foam supplier can help you develop firmness specifications to
serve your application objectives.
The following summary points are specific to the use of
flexible foam in upholstered furniture. (Future issues of IN•TOUCH®
will address firmness considerations specific to carpet cushion and mattress
applications.)
6. In specifying foam firmness, all characteristics of the application must
be considered, including: cushion surface dimensions, cushion thickness,
surface wrap and layered construction, cushion oversizing, upholstery
fabric, cover upholstering technique, spring system, decking construction,
Total Vertical Motion (TVM), ride and interfacial pressure dispersion
objectives.
7. Compression Modulus (Support Factor) calculations can be used with
"high performance" foam products to reduce surface firmness while
maintaining deep down support, or to increase support and insulation
performance while maintaining surface firmness.
This information is provided as a service of the Polyurethane Foam
Association to improve the understanding of key issues that affect
flexible polyurethane foam cushioning. To learn more about specific
foams, contact your foam supplier.
This bulletin is intended to serve as a reference regarding the general properties and uses
of polyurethane foam, and has been developed as a service for the Polyurethane Foam
Association's (PFA) members and their customers. The information contained in this
bulletin is offered in good faith, developed from sources deemed to be reliable, and
believed to be accurate when prepared, but is offered without warranty, express or implied,
as to merchantability, fitness for a particular purpose, or any other matter. The PFA and its
member disclaim all responsibility for any loss or damage arising from reliance on such
information by any party. This bulletin is not intended to be all inclusive on any subject
matter. The PFA makes no endorsements, assurances, warranties, or guarantees
concerning the quality, uses, or applications of polyurethane foam or specific products
produced from polyurethane foam. PFA does not endorse the proprietary products or
processes of any manufacturer. PFA and its members do not assume any responsibility for
compliance with applicable laws and regulations. The PFA makes no representations
regarding the combustibility of polyurethane foam under different applications or in
different formulations. It is the responsibility of readers and purchasers or users of
polyurethane foam to acquaint themselves with its combustibility characteristics both as to
usage and storage, and any questions concerning applications and the combustibility of
polyurethane foam must be directed to individual foam manufacturers or suppliers.
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©1994, Polyurethane Foam Association, Inc. All rights reserved. This document
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